WO2016090533A1 - Electronic cigarette designs for automated manufacturing - Google Patents

Electronic cigarette designs for automated manufacturing Download PDF

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Publication number
WO2016090533A1
WO2016090533A1 PCT/CN2014/093275 CN2014093275W WO2016090533A1 WO 2016090533 A1 WO2016090533 A1 WO 2016090533A1 CN 2014093275 W CN2014093275 W CN 2014093275W WO 2016090533 A1 WO2016090533 A1 WO 2016090533A1
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WO
WIPO (PCT)
Prior art keywords
tube
electronic cigarette
control module
module
heater module
Prior art date
Application number
PCT/CN2014/093275
Other languages
French (fr)
Inventor
Ka kui HO
Original Assignee
Fontem Holdings 2 B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fontem Holdings 2 B.V. filed Critical Fontem Holdings 2 B.V.
Priority to EP14907963.4A priority Critical patent/EP3229619B1/en
Priority to CN201480084522.2A priority patent/CN107205476B/en
Priority to PL14907963T priority patent/PL3229619T3/en
Priority to PCT/CN2014/093275 priority patent/WO2016090533A1/en
Priority to TW104141129A priority patent/TW201626908A/en
Publication of WO2016090533A1 publication Critical patent/WO2016090533A1/en

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/02—Details
    • H05B3/04—Waterproof or air-tight seals for heaters
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/70—Manufacture
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
    • H05B3/44—Heating elements having the shape of rods or tubes non-flexible heating conductor arranged within rods or tubes of insulating material
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/10—Devices using liquid inhalable precursors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/014—Heaters using resistive wires or cables not provided for in H05B3/54
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/021—Heaters specially adapted for heating liquids
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/022—Heaters specially adapted for heating gaseous material

Definitions

  • the field of the invention is the design and manufacture of electronic cigarettes.
  • An electronic cigarette generally has a battery, an atomizer having a heating element, a container of liquid, and an electronic control circuit linked to the battery, the heating element, and an inhalation sensor.
  • the inhalation sensor detects the inhalation and the control circuit provides electrical current from the battery to the heating element.
  • the heating element heats liquid to create vapor, which is inhaled by the user.
  • Fig. 1 is an exploded perspective view of e-cigarette components.
  • Fig. 2 is a perspective view of an e-cigarette tube.
  • Fig. 3 is a perspective view of the components of Fig. 1 installed in the tube shown in Fig. 2.
  • Fig. 4 is rear perspective view of the heater module shown in Fig. 1.
  • Fig. 5 is a side perspective view of the heater module shown in Fig. 4.
  • FIG. 6 rear perspective view of the electronic control module shown in Fig. 1.
  • Fig. 7 is a front and side perspective view of the control module shown in Fig. 6.
  • Fig. 8 is a side perspective view of the heater and control modules electrically connected via a connector strip, as shown in Fig. 1.
  • Figs. 9A-9D show an example of an assembly method.
  • Fig. 10 is an enlarged side view of the battery, the heater module and the liquid supply installed within the tube.
  • Fig. 11 is an enlarged side view of the front end of the e-cigarette shown in Fig. 3 with the front cap installed.
  • an e-cigarette 20 includes components that may be assembled together and then installed into a tube 22.
  • the tube 22 may be a thin-wall metal tube, for example stainless steel, having a length and diameter similar to a conventional tobacco cigarette, typically 80-120 mm long and a diameter of 8-12 mm.
  • the components of the e-cigarette 20 may include a control module 24 and a heater module 50 located on opposite sides of a battery 28.
  • a connector strip 30 may be used to provide an electrical connection between the control module 24 and the heater module 50, instead of using conventional wiring.
  • the e-cigarette 20 may further include a PCB or heater plate 64 positioned between the heater module 50 and a liquid supply 72.
  • the components 24, 28, 50, and 72 are generally cylindrical or disk-shaped, and have outside diameters nominally smaller than the inner diameter of the tube 22. This allows installation of the components into the tube22 by sliding the components into the tube 22 from either open end of the tube. As shown in Figs. 3 and 11, an O-ring 36 on the control module 24 holds the control module 24 in place near the front end of the tube 22. A front cap 26 snaps onto the tube 22 to close off the open front end of the tube. Similarly, a mouth cap 80 snaps onto the back end of the tube 22.
  • the heater module 50 may be provided with an O-ring 54 around a cylindrical housing 52.
  • the heater module 50 may have a wire coil 60 or similar heating element on or at the back end of the heater module housing 52, with the wire coil used to vaporize liquid.
  • the wire coil 60 has a central axis AA perpendicular to the longitudinal axis LL of the tube 22.
  • Wire leads 62 of the wire coil 60 may pass through openings in a heater plate 64 and extend into the heater module housing 52.
  • a second electrical contact 68 which may be in an opening in the side of the heater module housing 52 is electrically connected to the other wire lead 62 and to the back end of the connector strip 30, as shown in Fig. 10.
  • a clip 56 may optionally be provided on the side of the heater module housing 52, to make electrical contact between the tube 22 and the heater module 50, and/or to help hold the heater module 50 in place within the tube 22.
  • the heater module 50 may also have a switch 58 which may be used to prevent electrical current from flowing to the wire coil 60, regardless of the control operation provided by the control module 24.
  • control module 24 may also have a cylindrical housing 46, an O-ring 36 and a clip 38, similar to the heater module 50.
  • Axial air holes 44 may extend through the housing 46 to vent the battery compartment 48 formed in the tube 22 between the control module 24 and the heater module 50.
  • An LED 42 may be provided on the front end of the control module housing 48.
  • An end contact 40 on the back end of the control module housing 46 is electrically connected to the front end of the connector strip 30 via an internal conductor 45, as shown in Fig. 11.
  • the connector strip 30 electrically connects the control module 24 to the heater module 50.
  • the connector strip may be made of a plastic material, such as polyethylene terephthalate (PET) having a conductive coating.
  • PET polyethylene terephthalate
  • the connector strip may be thin (e.g. 0.5 to 1.5 mm) and curved to match and lay flat against the inside diameter of the tube.
  • the ends of the connector strip 30 may be formed or bent up into tabs 32 that insert into side openings in the control module housing 46 and the heater module housing 52, to make electrical connections. With the components assembled into the tube 22, the tabs 32 cannot pull out from the modules 24 and 50, so that reliable electrical connections are made.
  • the control module 24 is connected to the anode of the battery directly via the end contact 40, and to the cathode of the battery through the spring 66 and the contact strip 30.
  • the connector strip 30 may have multiple separate conductive lines to provide power and signals between the control module 24 and the heater module 50. Use of the connector strip 30 allows the e-cigarette to be manufactured without the need for wiring or soldering. It also allows the battery to be easily removed from the tube 22 for recycling or separate disposal.
  • the tube 22 itself, or a conductive plated layer on the inside of the tube 22, may also optionally be used as an additional electrical conductor between them.
  • a gasket 70 such as a wooden fiber gasket, may be attached to the liquid supply 72.
  • the liquid supply 72 may be a PET filter material within a plastic or metal tube 74, with a central passageway 76 extending through the liquid supply 72 from the mouth cap 80 to the heater module 50.
  • the control module 24, the battery 28, the heater module 50 and the liquid supply 72 may be aligned and brought together on or in a fixture to form a component group.
  • the connector strip 30 is installed with the tabs 32 inserted into contact openings in the control module housing 46 and in the heater module housing 52.
  • a fourth assembly step shown in Fig. 9D the component group, now including the conductor strip, is moved e.g., pushed into the tube 22.
  • the final assembly step is shown in Fig. 3, with the mouth cap 80 and the front cap 26 pressed or snapped onto the ends of the tube 22.
  • the outer diameters of the O-rings 36 and 54 may be nominally larger than the inside diameter of the tube 22. In this case, the O-rings are compressed slightly when installed into the tube 22, creating sufficient frictional forces to securely hold the components in place within the tube 22. The O-rings may also help to block leakage of any stray liquid within the tube 22.
  • the e-cigarette 20 has fewer discrete components.
  • Each of the components is substantially cylindrical or disk-shaped. Consequently, the components may be queued and up and handled via automation or robotics.
  • the components may be positioned into a holder or fixture via a robot, in axial alignment with the tube 22, and then pushed into the tube 22.In this case the only remaining assembly steps are installing the front cap 26 and the mouth cap 80, which may also be done via automation.
  • no screw threads, soldering, wire positioning, heat shrinkage tubing, etc. are used or needed.

Abstract

An electronic cigarette (20) includes a control module (24), a battery (28), a heater module (50) and a liquid supply (72) within a tube (22). The control module (24) and the heater module (50) are positioned on opposite sides of the battery (28) and are electrically connected to each other via a connector strip (30). The connector strip (30) may have tabs (32) extending into the control module (24) and the heater module (50), to make electrical connections. The electronic cigarette (20) may be free of screw threads on any element and have no soldered connections, to improve reliability and to allow for automated manufacturing.

Description

ELECTRONIC CIGARETTE DESIGNS FOR AUTOMATED MANUFACTURING Field of the Invention
The field of the invention is the design and manufacture of electronic cigarettes.
Background of the Invention
Use of electronic cigarettes or so-called e-cigarettes is rapidly expanding as an alternative to smoking conventional real tobacco cigarettes. An electronic cigarette generally has a battery, an atomizer having a heating element, a container of liquid, and an electronic control circuit linked to the battery, the heating element, and an inhalation sensor. When the user inhales, the inhalation sensor detects the inhalation and the control circuit provides electrical current from the battery to the heating element. The heating element heats liquid to create vapor, which is inhaled by the user.
Even with the rapid growth of e-cigarettes, they are largely still manufactured by hand, often including electrical connections made via soldering manually. Hand assembly of e-cigarettes limits production capacity and stability. It can also affect quality control, result is inefficient use of materials, and largely prevents achieving the cost savings associated with automated manufacturing.
Many e-cigarettes are sold as single-use or disposable products. In these e-cigarettes, the battery is necessarily discarded with the e-cigarette when the liquid supply is exhausted. This may limit the types of batteries that may be used in the e-cigarette, and/or create environmental battery disposal complications. Notwithstanding  the motivation to overcome these disadvantages, various engineering challenges remain in providing improved e-cigarette designs and methods of e-cigarette manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, the same reference number indicates the same element in each of the views.
Fig. 1 is an exploded perspective view of e-cigarette components.
Fig. 2 is a perspective view of an e-cigarette tube.
Fig. 3 is a perspective view of the components of Fig. 1 installed in the tube shown in Fig. 2.
Fig. 4 is rear perspective view of the heater module shown in Fig. 1.
Fig. 5 is a side perspective view of the heater module shown in Fig. 4.
Fig. 6 rear perspective view of the electronic control module shown in Fig. 1.
Fig. 7 is a front and side perspective view of the control module shown in Fig. 6.
Fig. 8 is a side perspective view of the heater and control modules electrically connected via a connector strip, as shown in Fig. 1.
Figs. 9A-9D show an example of an assembly method.
Fig. 10 is an enlarged side view of the battery, the heater module and the liquid supply installed within the tube.
Fig. 11 is an enlarged side view of the front end of the e-cigarette shown in Fig. 3 with the front cap installed.
DETAILED DESCRIPTION
A novel e-cigarette design is provided. Novel methods for manufacturing an e-cigarette are also disclosed. Turning now in detail to the drawings, as shown in Figs. 1 and 2, an e-cigarette 20 includes components that may be assembled together and then installed into a tube 22. The tube 22 may be a thin-wall metal tube, for example stainless steel, having a length and diameter similar to a conventional tobacco cigarette, typically 80-120 mm long and a diameter of 8-12 mm. In the example shown, the components of the e-cigarette 20 may include a control module 24 and a heater module 50 located on opposite sides of a battery 28. A connector strip 30 may be used to provide an electrical connection between the control module 24 and the heater module 50, instead of using conventional wiring. Referring still to Fig. 1, in the example shown, the e-cigarette 20 may further include a PCB or heater plate 64 positioned between the heater module 50 and a liquid supply 72.
As shown in Figs. 1 and 3, the  components  24, 28, 50, and 72 are generally cylindrical or disk-shaped, and have outside diameters nominally smaller than the inner diameter of the tube 22. This allows installation of the components into the tube22 by sliding the components into the tube 22 from either open end of the tube. As shown in Figs. 3 and 11, an O-ring 36 on the control module 24 holds the control module 24 in  place near the front end of the tube 22. A front cap 26 snaps onto the tube 22 to close off the open front end of the tube. Similarly, a mouth cap 80 snaps onto the back end of the tube 22.
Referring now to Figs. 4 and 5, the heater module 50 may be provided with an O-ring 54 around a cylindrical housing 52. The heater module 50 may have a wire coil 60 or similar heating element on or at the back end of the heater module housing 52, with the wire coil used to vaporize liquid. In the example of Figs. 4 and 5, the wire coil 60 has a central axis AA perpendicular to the longitudinal axis LL of the tube 22. Wire leads 62 of the wire coil 60 may pass through openings in a heater plate 64 and extend into the heater module housing 52. A first electrical contact 66 on or at the front end of the heater module housing 52, optionally in the form of a spring, connects to one of the wire leads 62. A second electrical contact 68 which may be in an opening in the side of the heater module housing 52 is electrically connected to the other wire lead 62 and to the back end of the connector strip 30, as shown in Fig. 10. A clip 56 may optionally be provided on the side of the heater module housing 52, to make electrical contact between the tube 22 and the heater module 50, and/or to help hold the heater module 50 in place within the tube 22. The heater module 50 may also have a switch 58 which may be used to prevent electrical current from flowing to the wire coil 60, regardless of the control operation provided by the control module 24.
As shown in Figs. 6 and 7, the control module 24 may also have a cylindrical housing 46, an O-ring 36 and a clip 38, similar to the heater module 50. Axial air holes 44 may extend through the housing 46 to vent the battery compartment 48 formed in the tube 22 between the control module 24 and the heater module 50. An LED 42 may be  provided on the front end of the control module housing 48. An end contact 40 on the back end of the control module housing 46 is electrically connected to the front end of the connector strip 30 via an internal conductor 45, as shown in Fig. 11.
As shown in Fig. 8, the connector strip 30 electrically connects the control module 24 to the heater module 50. The connector strip may be made of a plastic material, such as polyethylene terephthalate (PET) having a conductive coating. The connector strip may be thin (e.g. 0.5 to 1.5 mm) and curved to match and lay flat against the inside diameter of the tube. As shown in Figs. 2, 10 and 11, the ends of the connector strip 30 may be formed or bent up into tabs 32 that insert into side openings in the control module housing 46 and the heater module housing 52, to make electrical connections. With the components assembled into the tube 22, the tabs 32 cannot pull out from the  modules  24 and 50, so that reliable electrical connections are made. Referring once again to Figs. 1 and 8, with the e-cigarette 20 assembled, the control module 24 is connected to the anode of the battery directly via the end contact 40, and to the cathode of the battery through the spring 66 and the contact strip 30.
The connector strip 30 may have multiple separate conductive lines to provide power and signals between the control module 24 and the heater module 50. Use of the connector strip 30 allows the e-cigarette to be manufactured without the need for wiring or soldering. It also allows the battery to be easily removed from the tube 22 for recycling or separate disposal. The tube 22 itself, or a conductive plated layer on the inside of the tube 22, may also optionally be used as an additional electrical conductor between them.
As shown in Fig. 9A, in an initial assembly step, a gasket 70, such as a wooden fiber gasket, may be attached to the liquid supply 72. The liquid supply 72 may be a PET filter material within a plastic or metal tube 74, with a central passageway 76 extending through the liquid supply 72 from the mouth cap 80 to the heater module 50. In a second assembly step as shown in Fig. 9B, the control module 24, the battery 28, the heater module 50 and the liquid supply 72 may be aligned and brought together on or in a fixture to form a component group. Referring to Fig. 9C, in a third assembly step the connector strip 30 is installed with the tabs 32 inserted into contact openings in the control module housing 46 and in the heater module housing 52. In a fourth assembly step shown in Fig. 9D, the component group, now including the conductor strip, is moved e.g., pushed into the tube 22. The final assembly step is shown in Fig. 3, with the mouth cap 80 and the front cap 26 pressed or snapped onto the ends of the tube 22.
The outer diameters of the O- rings  36 and 54 may be nominally larger than the inside diameter of the tube 22. In this case, the O-rings are compressed slightly when installed into the tube 22, creating sufficient frictional forces to securely hold the components in place within the tube 22. The O-rings may also help to block leakage of any stray liquid within the tube 22.
Referring back to Figs. 1-3, in comparison to existing e-cigarettes, the e-cigarette 20 has fewer discrete components. Each of the components is substantially cylindrical or disk-shaped. Consequently, the components may be queued and up and handled via automation or robotics. For example, the components may be positioned into a holder or fixture via a robot, in axial alignment with the tube 22, and then pushed into the tube  22.In this case the only remaining assembly steps are installing the front cap 26 and the mouth cap 80, which may also be done via automation. Unlike many existing e-cigarettes, no screw threads, soldering, wire positioning, heat shrinkage tubing, etc. are used or needed.
Thus, a novel e-cigarette and manufacturing methods have been shown and described. Various changes and substitutions may of course be made without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents. References here to the e-cigarette being free of soldered connections and wiring refers to the components shown in the drawings, and not to any connections, wiring, or component inside of the control or heating modules, such as microelectronic components having soldered connections or wiring.

Claims (12)

  1. An electronic cigarette, comprising:
    a tube；
    a control module, abattery, aheater module and a liquid supply within the tube, with the control module and the heater module on opposite sides of the battery, and with the control module and the heater module each having a cylindrical housing； and
    a connector strip electrically connecting the heater module to the control module, without wiring.
  2. The electronic cigarette of claim 1 with the tube comprising a continuous integral single piece tube.
  3. The electronic cigarette of claim 1 with the connector strip having a first end tab extending into the control module housing and a second tab extending into the heater module housing.
  4. The electronic cigarette of claim 1 having no screw threads on any element.
  5. The electronic cigarette of claim 1 having no soldered connections.
  6. The electronic cigarette of claim 1 further comprising a battery contact spring on a front end of the heater module and a wire coil on a back end of the heater module.
  7. The electronic cigarette of claim 1 with the connector strip comprising the only electrical connections between the control module and the heater module.
  8. The electronic cigarette of claim 3 comprising a single connector strip having a central region with a curvature substantially matching the inside diameter of the tube, with the end tabs perpendicular to the central region.
  9. A method for manufacturing an electronic cigarette, comprising:
    positioning a control module, abattery, aheater module and a liquid supply in sequence and in axial alignment with each other to form a component group；
    installing a connector strip electrically connecting the control module and the heater module；
    aligning a tube with the component group；
    moving the tube and/or the component group to position the component group entirely within the tube； and
    placing end caps onto the ends of the tube.
  10. The method of claim 9 with the electronic cigarette having no soldered connections.
  11. The method of claim 9 with the electronic cigarette having no threaded components.
  12. The method of claim 9 with the steps performed via automation or robotically.
PCT/CN2014/093275 2014-12-08 2014-12-08 Electronic cigarette designs for automated manufacturing WO2016090533A1 (en)

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EP14907963.4A EP3229619B1 (en) 2014-12-08 2014-12-08 Electronic cigarette designs for automated manufacturing
CN201480084522.2A CN107205476B (en) 2014-12-08 2014-12-08 Electronic cigarette design for automated manufacturing
PL14907963T PL3229619T3 (en) 2014-12-08 2014-12-08 Electronic cigarette designs for automated manufacturing
PCT/CN2014/093275 WO2016090533A1 (en) 2014-12-08 2014-12-08 Electronic cigarette designs for automated manufacturing
TW104141129A TW201626908A (en) 2014-12-08 2015-12-08 Electronic cigarette designs for automated manufacturing

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USD848057S1 (en) 2016-06-23 2019-05-07 Pax Labs, Inc. Lid for a vaporizer
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PL3229619T3 (en) 2019-12-31
TW201626908A (en) 2016-08-01

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